Method and apparatus for producing an aqueous paint composition from a plurality of premixed compositions

ABSTRACT

The present invention is directed to the provision of premixed aqueous compositions which are used to provide a paint composition of varying finish characteristics at the point of sale. Thus, the merchant distributing the paint composition made from the subject premixed compositions need only maintain inventory of four compositions. The particular compositions which are the subject of the invention exhibit stable characteristics during storage in their respective reservoirs. The compositions include a pigment composition, a dispersant thickening agent, a high resin content binder, and a low resin content binder. The compositions are combined in differing amounts to produce paint compositions being suitable for either interior or exterior use and having differing sheens, quality levels, and color bases.

RELATED APPLICATION

This application is a continuation of the earlier patent applicationentitled “METHOD OF PRODUCING AN AQUEOUS PAINT COMPOSITION FROM APLURALITY OF PREMIXED COMPONENTS”, Ser. No. 09/578,001, filed May, 24,2000, which is a continuation-in-part of the earlier patent applicationentitled “METHOD OF PRODUCING AN AQUEOUS PAINT COMPOSITION FROM APLURALITY OF PREMIXED COMPONENTS”, Ser. No. 09/221,332, filed Dec. 23,1998, and issued as U.S. Pat. No. 6,221,145 on Apr. 24, 2001.

BACKGROUND OF THE INVENTION

1. Technical Field

This invention relates to the production of an aqueous paint from aplurality of premixed compositions.

2. Background Art

The traditional manufacture of paint has utilized processes whichcontinuously fill containers with a neutral or base color at the centralfacility. The containers are transported to the point of use or point ofsale and stored until use or resale. The transport and storage in theindividual containers adds significantly to the cost of the sold productfor it is necessary to inventory a wide variety of paints havingdifferent finish characteristics to satisfy consumer demand. Forexample, the finishes offered for sale range from the traditional flatpaint through varying resin compositions up to a high gloss finish.Inventory is maintained for all the different finishes at the point ofsale by the merchant.

The manufacture of paint at the central facility can be either a batchprocess or an extended continuous mixing process. The process typicallycalls for mixing a pigment containing ground titanium dioxide along witha thickener, a viscosity controlling agent and resin added to the waterbase. The pigment is a composition with a high percentage solidssuspended in water. Storage for any significant period of time of apremixed pigment composition typically results in settling and anon-uniform distribution of constituents throughout the premix.Consequently, manufacturing processes are designed to limit theresidence time in premixing containers in order to promote themanufacture of more uniform products.

DISCLOSURE OF INVENTION

The present invention is directed to the provision of prepaints, whichare fluid prepaint compositions or premixed aqueous compositions whichcan be used to provide a paint mixture of varying finish characteristicsat the point of sale. Thus, the merchant distributing the paintcomposition made from the subject premixed compositions need onlymaintain inventory of four compositions. The particular compositionswhich are the subject of the invention exhibit stable characteristicsduring storage in their respective reservoirs.

According to the present invention, an apparatus includes a first supplyreservoir containing a first premixed composition. The first compositionmay be any one of four compositions, the four compositions including apigment composition, a dispersant thickening agent, a high resin contentbinder, and a low resin content binder. The apparatus also includes asecond supply reservoir containing a second premixed composition that isanother of the four compositions. A first valve is fluidly connected tothe first supply reservoir and a second valve fluidly connected to thesecond supply reservoir. An actuator system is connected to the firstvalve and the second valve. A receiving reservoir is fluidly connectedto the first valve and the second valve, and a measuring system measuresa first flow amount of the first premixed composition supplied from thefirst supply reservoir to the receiving reservoir and measures a secondflow amount of the second premixed composition supplied from the secondsupply reservoir to the receiving reservoir. A control system isconnected to the measuring system. The measuring system emits a firstamount signal that represents the first flow amount and a second amountsignal that represents the second flow amount, and the control systemreceives the first amount signal and the second amount signal. Thecontrol system emits a first close signal to the actuator system whenthe first amount signal indicates that the first flow amount equals afirst predetermined amount, thereby prompting the actuator system toclose the first valve. The control system emits a second close signal tothe actuator system when the second amount signal indicates that thesecond flow amount equals a second predetermined amount, therebyprompting the actuator system to close the second valve.

A method of producing an aqueous paint composition or fluid prepaint isalso provided. The method includes storing a first premixed compositionin a first supply reservoir. The first composition may be any one offour compositions, the four compositions including a pigmentcomposition, a dispersant thickening agent, a high resin content binder,and a low resin content binder. The apparatus also includes a secondsupply reservoir containing a second premixed composition that isanother of the four compositions. The method also includes storing asecond premixed composition that is another of the four compositions ina second supply reservoir. The method determines a first predeterminedamount of the first premixed composition and a second predeterminedamount of the second premixed composition. The first premixedcomposition is supplied from the first supply reservoir to a receivingreservoir, and the second premixed composition is supplied from thesecond supply reservoir to the receiving reservoir. A first flow amountof the first premixed composition supplied from the first supplyreservoir to the receiving reservoir and a second flow amount of thesecond premixed composition supplied from the second supply reservoir tothe receiving reservoir are measured. Supply of the first premixedcomposition is ceased when the first flow amount equals the firstpredetermined amount and supply of the second premixed composition isceased when the second flow amount equals the second predeterminedamount.

The method of producing a desired paint composition may includeprompting a user to input into an apparatus a selection of eitherinterior or exterior paint, prompting the user to input into theapparatus a desired sheen, prompting a user to input into the apparatusa desired quality, prompting a user to input into the apparatus adesired color type, and automatically producing the desired paintcomposition. The step of automatically producing the desired paintcomposition is performed by the apparatus so that the paint compositionhas the desired sheen and the desired quality. The desired paintcomposition is also well-suited for the desired color type and foreither interior or exterior use as desired.

The invention also includes a program product including a controlprogram that prompts a user to input a selection of paint that iswell-suited for interior use or paint that is well-suited for exterioruse, a desired sheen, a desired quality, and a desired color type. Thecontrol program also controls an apparatus to produce the desired paintcomposition. The desired paint composition has the desired sheen and thedesired quality. The desired paint composition is also well-suited forthe desired color type and for either interior or exterior use asdesired. The program product also includes signal bearing media bearingthe control program.

Another method of producing an aqueous paint composition according tothe present invention includes placing a first premixed aqueouscomposition in a receiving reservoir. The first composition may be anyone of four compositions, the four compositions including a pigmentcomposition, a dispersant thickening agent, a high resin content binder,and a low resin content binder. This method also includes placing asecond premixed aqueous composition that is another of the fourcompositions in the receiving reservoir. The second aqueous compositionis also selected from the group of premixed aqueous compositions, butthe second aqueous composition is a different one of the group ofpremixed aqueous compositions than the first aqueous composition.

Another method of producing an aqueous paint composition includes mixinga first aqueous composition and a second aqueous composition. The firstcomposition may be any one of four compositions, the four compositionsincluding a pigment composition, a dispersant thickening agent, a highresin content binder, and a low resin content binder, but the secondaqueous composition is a different one of the four compositions than thefirst aqueous composition. This method includes storing the firstaqueous composition in a first supply reservoir and storing the secondaqueous composition in a second supply reservoir. The method alsoincludes supplying the first aqueous composition from the first supplyreservoir to the receiving reservoir and supplying the second aqueouscomposition from the second supply reservoir to the receiving reservoir.

The foregoing and other features and advantages of the invention will beapparent from the following more particular description of preferredembodiments of the invention, as illustrated in the accompanyingdrawings.

BRIEF DESCRIPTION OF DRAWINGS

The preferred embodiments of the present invention will hereinafter bedescribed in conjunction with the appended drawings, where likedesignations denote like elements.

FIG. 1 is a schematic view of an apparatus according to an embodiment ofthe present invention.

FIG. 2 is a perspective view of a portion of the apparatus of FIG. 1.

FIG. 3 is a schematic view of the circuitry of the apparatus of FIG. 1.

FIG. 4 is a flowchart depicting a method of producing a paintcomposition according to the present invention.

FIG. 5 is a flowchart depicting a method of maintaining an apparatusaccording to the present invention.

MODES FOR CARRYING OUT THE INVENTION

Four premixed aqueous compositions according to an embodiment of thepresent invention are sufficiently stable to be utilized at the point ofsale to the user to generate a water-based paint composition having thedesired finish characteristics. The four premixed aqueous compositionsare mixed to develop paints ranging from a flat finish to a high glossfinish. However, all four of the aqueous compositions are not used toproduce every paint composition.

The pigment-containing constituent or premixed pigment compositionpreferably contains titanium dioxide finely ground in an amount residingwithin the range of 40 to 50 percent by weight or a corresponding rangeof pigment volume concentrations (“PVC”) of the pigment. The titaniumdioxide is an opacifying pigment. The ground titanium dioxide is acommercially available product used in a wide variety of paintcompositions and its preparation techniques are well-known in theindustry. The titanium dioxide is added to water which comprises about25 percent of the resultant pigment composition. During the blendingprocess, a mixture of calcined clay and silica in an amount of 15percent by weight is added to maintain the titanium dioxide insuspension. A viscosity controlling agent is also added in an amount ofabout 10 percent of the resultant dispersion or pigment composition.

In order to maintain the titanium dioxide in a uniform dispersion, adispersant-thickener is added during blending in an amount of less than5 percent of the pigment composition. It has been found that thecombination of a commercially-available dispersant supplemented by theaddition of a phosphate-based dispersant such as potassium tri polyphosphate (KTPP) along with a modest amount of thickener enables thetitanium dioxide pigment dispersion to remain uniform in distributionwhile stored.

The commercially available dispersant sold as BUSPERSE (a federallyregistered trademark owned by Buckman Laboratories, Inc.) andmanufactured by Buckman Laboratories, Inc. is the primary dispersant andis added in amount of about 3.6 weight percent. In addition, thephosphate based dispersant KTPP is added in an amount of about 0.2weight percent to the pigment composition. It is believed that thephosphate ions in this additive replace the carbonate and other ions inthe water to enhance the wetting properties of the water and therebypromote the distribution of the titanium dioxide throughout. Thethickener added is a cellulosic thickening agent. Several arecommercially available for use in the manufacture of aqueous paintcompositions. One example is the thickener sold under the trademark 481by AKZO NOBEL (Sweden).

The novel combination of these additives to the combination of titaniumdioxide and water in the stated proportions has been found to enable theaqueous pigment composition to be used at point of sale to generate thewide scope of paint products. In tests of the pigment dispersion storedin a 55 gallon reservoir without agitation for a period of 2½ months, nodiscernible settling was noted. The addition of resin in an amount ofabout 5 percent of the dispersion has been found to aid in reducing thetime for the resultant paint to cure. T his factor is useful but tendsto reduce the storage time of the pigment dispersion and is utilizedonly when a reduced curing time is important to the user.

At the point of sale, three additional premixed aqueous compositions areavailable to custom prepare the desired paint. The second composition interms of likely usage is a dispersant-thickening agent which serves as adilutant. The second composition is predominantly water in an amount ofabout 93 percent by weight. There are three additional additives to thesecond composition. They include a phosphate-based dispersant such asthe potassium tri poly phosphate used in the pigment composition in anamount of less than 1 percent. The phosphate-based dispersant is addedalong with approximately a like amount of a cellulosic thickener. Thecombination of dispersant and thickener acts in the same manner as inthe pigment composition although it is to be noted that the amount ofthickener is several times that used in the pigment composition. Theadditional additive is a coalescent in an amount of 4 to 5 weightpercent. One commercial coalescent found suitable for use is sold underthe federally registered trademark TEXANOL by Eastman Kodak Company.

The dispersant-thickener agent is preferably used in formulating allpaint compositions with the exception of a high gloss finish paintcomposition. The third and fourth compositions available for mixing arethe resin-containing compositions. The low resin composition or prepaintis preferably about 50 percent resin by weight and about 28 percentwater. However, the percentage of resin by weight can be as low as 10percent. To this mixture of resin and water is added diatomaceous earthas a flattening agent in the amount of about 7 percent and a combinationof ground limestone and calcined clay at about 11 percent and about 3.5percent respectively. The combination of a dispersant and thickener areadded in the aggregate amount of about 1.2 percent to promote the samelong shelf life characteristic of the pigment composition.

The high resin component preferably contains resin in an amount of about80 percent, water at about 15 percent and a commercially-availablecoalescent at about 2 percent. However, the percentage of resin byweight can be as high as about 90 percent. The amount of resin and waterin the low and high resin compositions can be varied to achievedifferent finish characteristics. The resin utilized in the paintproducts formulated from the different combinations and found to providethe desired results is a 100 percent acrylic acrynol resin, such as theresin sold under the trademark 6183 by BASF. However, it is to be notedthat other commercially available resins can be used if desired.

The four above-discussed formulations have been determined to be stableand free from settling when stored in reservoirs for extended periods.To produce a desired paint product, each storage reservoir is coupledthrough fluid pumps and appropriate valving to dispensing outlets withthe discharge therefrom preferably being directed into the receivingreservoir which is preferably the point of sale container.

A flat finish product utilizes the dispersant thickening agent and lowresin composition. To produce the paint products referred to aseggshell, satin and low sheen finishes a portion of high resincomposition is added to the flat finish mixture. In the case of adesired semi-gloss finish paint, the high resin component is used as areplacement for the low resin component. A full gloss paint utilizes thehigh resin component, but not the dispersant thickening agent or the lowresin composition.

The four compositions can also be varied to produce varying qualitylevels and to produce paint compositions that are suitable for eitherinterior or exterior use and paint compositions having various colorbases so that they are suitable for use as different types of colors.

An interior paint composition will have less resin than a comparableexterior paint. Accordingly, interior paint compositions will have lessof the high resin and/or low resin compositions than a comparableexterior paint composition. Quality is increased by decreasing theamount of dispersant thickening agent in a paint composition andincreasing the amounts of the pigment composition and the low and highresin compositions. The amount of pigment composition is varied tochange the type of color for which the paint composition is well-suited.Generally white base requires more pigment composition than pastels,pastels require more pigment composition than tinting, tinting requiresmore pigment composition than deep tone, and deep tone requires morepigment composition than neutral base. Typically neutral base paintcompositions will not have any pigment composition.

The actual balances between the components for the different finishescan be varied in accordance with the needs of the purchaser for aparticular type of finish. For example, a particular purchaser mayrequire a paint composition that will have greater coverage. Also, coloradditives are added to vary the color of the paint after the fourpremixed aqueous compositions are added to form the basic paintcomposition.

Typical paint compositions suitable for programmed dispensing at thepoint of sale include the four aqueous compositions in the weightpercentages shown below:

High Finish Pigment Comp. Disp-Thickening Low Resin Resin Flat 32.5 24.942.6 0 Satin 38.8 17.9 10.2 33.1 Semi-Gloss 39.1 9.6 0 51.3 High-Gloss44.0 0 0 56.0

All the foregoing examples are typical for retail quality paintssuitable for exterior use with pastel colors. As can be appreciated fromthe disclosure provided herein, paint compositions may be provided bycombining a set of two or more premixed compositions or prepaints.

An apparatus 10 for producing an aqueous paint composition according tothe present invention will now be described with reference to FIGS. 1-5.Referring to FIG. 1, apparatus 10 includes four tanks that act as supplyor storage reservoirs 12, 14, 16, 18 for the four premixed aqueouscompositions described above. The premixed aqueous compositions can bestored in supply reservoirs 12, 14, 16, 18 for a significant period oftime. Preferably, the reservoirs are able to store the aqueouscompositions for at least one day, and more preferably for at least aweek. In a preferred embodiment, the reservoirs can store thecompositions for at least two and one half months. The desired amount ofeach of the four compositions is supplied to a bucket that acts as areceiving reservoir 20 for the desired aqueous paint composition.Preferably, receiving reservoir 20 is contained within the samecontainer that will house the paint when it is sold to a consumer.

First Reservoir 12, second reservoir 14, third reservoir 16, and fourthreservoir 18 are preferably large tanks that will contain enough of thefour compositions to last for a substantial period of time. In apreferred embodiment, first reservoir 12, second reservoir 14, thirdreservoir 16, and fourth reservoir 18 are each a 275 gallon polymercontainer. However, reservoirs 12, 14, 16, 18 may be any of severalother containers that are suitable for holding aqueous compositions.

First reservoir 12, second reservoir 14, third reservoir 16, and fourthreservoir 18 are preferably fluidly connected to first pump 30, secondpump 32, third pump 34, and fourth pump 36, respectively. First pump 30,second pump 32, third pump 34, and fourth pump 36 are preferably ¾ inchrotary gear pumps available under the model number 1V426 from W. W.Grainger, Inc. A first motor 40, second motor 42, third motor 44, andfourth motor 46 power first pump 30, second pump 32, third pump 34, andfourth pump 36, respectively. Motors 40, 42, 44, 46 are preferably 0.75horsepower electric motors model number 4K858AA available from W. W.Grainger, Inc. Motors 40, 42, 44, 46 are preferably mechanicallyconnected to pumps 30, 32, 34, 36, respectively by a drive belt andpulley assembly or other suitable mechanical drive connection. However,pumps 30, 32, 34, 36 may be other types of pumps and they may be poweredin some other way. Also, other types of fluid transmitting systems, suchas gravity feed systems may be used.

First pump 30, second pump 32, third pump 34, and fourth pump 36 arepreferably fluidly connected to first valve 50, second valve 52, thirdvalve 54, and fourth valve 56, respectively. First valve 50, secondvalve 52, third valve 54, and fourth valve 56 are actuated by anactuator system that preferably includes a first solenoid 60, secondsolenoid 62, third solenoid 64, and a fourth solenoid 66. Each solenoid60, 62, 64, 66 preferably actuates a corresponding valve 50, 52, 54, 56.In a preferred embodiment, each solenoid-valve combination is thesolenoid-valve combination available under the model number VE075 fromRain for Rent. However, those skilled in the art will appreciate thatthe valves 50, 52, 54, 56 may be a single four-way valve, and thatsolenoids 60, 62, 64, 66 may be a four-way actuator that is able toactuate valves 50, 52, 54, 56. Valves 50, 52, 54, 56 are fluidlyconnected to receiving reservoir 20. In a preferred embodiment, valves50, 52, 54, 56 are positioned above receiving reservoir 20 so thatfluids passing through valves 50, 52, 54, 56 drop directly intoreceiving reservoir 20 (see FIG. 2).

The fluid lines connecting the various components of apparatus 10 arepreferably 0.75 inch inside diameter flexible polyvinyl chloride lines.However, they may be any of various lines that are sufficient totransfer fluids between reservoirs, pumps, and valves.

Receiving reservoir 20 is preferably a paint bucket that is suitable forcontaining paint when it is sold to a consumer. However, receivingreservoir 20 may be any type of container that will contain an aqueouspaint composition.

Receiving reservoir 20 is seated on a scale or measuring system 70 thatis connected to and emits a signal to a control 80 that represents theweight of reservoir 20. Scale 70 is preferably a model number CX 086scale available from Aztech Controls Corp. in Mesa, Ariz. Flow meters orsome other measuring system could be used to measure the flow amounts ofeach of the compositions into receiving reservoir 20.

Control 80 is preferably a programmable logic control system, such asthe programmable logic control (PLC) system available from QuantumAutomation in Tustin, Calif. that includes a housing unit having modelnumber D2-06B, which houses units having model numbers D2-250, D2-08ND3,and F2-04AD-1, and two units having the model number D2-08TR. Theelectrical position and function of each of these units will bedescribed in more detail below. Control 80 is connected to and emitscontrol signals to motors 40, 42, 44, 46 to turn motors 40, 42, 44, 46on and off. Control 80 is also connected to and emits control signals tosolenoids 60, 62, 64, 66 to prompt solenoids 60, 62, 64, 66 to open andclose valves 50, 52, 54, 56.

Control 80 is connected to and emits signals to a user interface that ispreferably a touch screen 90 to prompt a user to input information.Additionally, touch screen 90 emits signals to control 80 that representinput from the user. Touch screen 90 is preferably a model numberDP-C320 touch screen available from Quantum Automation. However, any ofseveral touch screens would be sufficient as touch screen 90.

An emergency stop switch 92 is connected to control 80 so that when stopswitch 92 is activated, stop switch 92 emits a signal to control 80 thatwill cause control 80 to turn motors 40, 42, 44, 46 off and to actuatesolenoids 60, 62, 64, 66 to close valves 50, 52, 54, 56. Additionally, areceiving reservoir position indicator 94 is connected to control 80 sothat when receiving reservoir 20 is not correctly positioned indicator94 will send a signal to control 80 that, like the stop switch signal,will cause control 80 to turn motors 40, 42, 44, 46 off and to actuatesolenoids 60, 62, 64, 66 to close valves 50, 52, 54, 56.

Referring to FIG. 2, emergency stop switch 92 is preferably activatedand deactivated by a button located on the front of a frame 96 thathouses valves 50, 52, 54, 56; solenoids 60, 62, 64, 66; scale 70 (notshown in FIG. 2); control 80 (not shown in FIG. 2); and touch screen 90.Preferably indicator 94 includes a lever that is depressed whenreceiving reservoir 20 is correctly positioned to receive aqueouscompositions from valves 50, 52, 54, 56. Frame 96 preferably also housesa conveyor 98 that includes a series of rollers for easily movingbuckets filled with aqueous solution away from valves 50, 52, 54, 56 andscale 70.

FIG. 3 depicts the circuitry for supplying electrical power to thevarious electrical components of apparatus 10. A power source 110supplies 240 volt 60 Hertz AC electrical power to main power lines 112.A 24 volt DC circuit 114 includes a pair of lines extend from main powerlines 112 to a 24 volt AC to DC converter 116. 24 volt converter 116 isgrounded by a ground connection 118. A high voltage line 120 extendsfrom 24 volt converter 116 that is at a positive 24 volts relative toground. A low voltage line 122 extends from 24 volt converter 116 thatis grounded by a ground connection 124.

A transducer unit 130 of control 80 is connected to high voltage line120 and low voltage line 122. Transducer unit 130 is preferably a fourchannel analog input having the model number F2-04AD-1 unit discussedabove. Scale 70 is connected to high voltage line 120 and is grounded bya ground connection 132 to provide electrical power for scale 70. Also,an output line 134 extends from scale 70 to transducer unit 130 to carrya signal representing the weight of an object carried on scale 70.

A switch unit 140 of control 80 is connected to high voltage line 120and is connected to low voltage line 122 via emergency stop switch 92and position indicator 94 so that if either emergency stop switch 92 orposition indicator 94 are open then power will cease being supplied toswitch unit 140 and to the remainder of the PLC units. Switch unit 140is preferably the model number D2-08ND3 unit discussed above.

A motor control unit 142 is preferably connected to high voltage line120. Motor control unit 142 includes four parallel connections to lowvoltage line 122, with each parallel connection extending via a motorswitch. Thus, a first motor switch 150, a second motor switch 152, athird motor switch 154, and a fourth motor switch 156 are arranged inparallel so that motor switches 150, 152, 154, 156 are powered by 24volt circuit 114. Emergency stop switch 92 is arranged in series withmotor switches 150, 152, 154, 156 in addition to being connected toswitch unit 140 above to provide an additional safeguard and assure thatmotors 40, 42, 44, 46 will be turned off if emergency stop switch 92 isactivated. Motor control unit 142 is preferably one of the model numberD2-08TR units discussed above.

Touch screen 90 is preferably connected to high voltage line 120 and lowvoltage line 122 to provide electrical power for touch screen 90.

A memory unit 160 is preferably connected directly to each of the mainpower lines 112 and it is grounded by ground connection 162. Memory unit160 preferably includes the programmable memory that will embody controlprogramming for control 80, including recipes for different paintcompositions to be produced by apparatus 10. Memory unit 160 ispreferably the model number D2-250 unit discussed above.

A 12 volt DC circuit 170 includes a 12 volt AC to DC converter 172 thatis connected to main power lines 112. A high voltage line 174 that is at12 volts relative to ground extends from 12 volt converter 172. A lowvoltage line 176 extending from 12 volt converter 172 is grounded by aground connection 178. A solenoid control unit 190 includes fourparallel connections to high voltage line 174. Solenoid control unit 190also includes four parallel connections to low voltage line 176, witheach parallel connection extending via a solenoid. Thus, first solenoid60, second solenoid 62, third solenoid 64, and a fourth solenoid 66 arearranged in parallel. Each solenoid 60, 62, 64, 66 is grounded by aground connection 192, 194, 196, 198, respectively. Each solenoidcontrol unit is preferably one of the model number D2-08TR unitsdiscussed above.

First motor 40 is connected to main power lines 112 via first motorswitch 150; second motor 42 is connected to main power lines 112 viasecond motor switch 152; third motor 44 is connected to main power lines112 via third motor switch 154; and fourth motor 46 is connected to mainpower lines 112 via fourth motor switch 156. Thus, motor switches 150,152, 154, 156 receive power for actuation from 24 volt circuit 114, butwhen they are open they prohibit the AC circuits to motors 40, 42, 44,46 from being completed.

The operation and use of apparatus 10 will now be described withreference to FIGS. 1-4. It is to be understood that the various promptsmade by touch screen 90 are activated by control 80, which sends signalsto touch screen 90 and receives signals from touch screen 90. Whenapparatus 10 is not in operation, it is in a dormant state 210, whereinpower is being supplied to various components, but none of them arefunctioning. In dormant state 210, touch screen 90 typically shows alogo or some other nonfunctional graphic. A user may activate apparatus10 by touching touch screen 90, whereupon touch screen 90 shows anumber/attribute prompt 212, which prompts a user to select eitherselection by recipe number 214 or selection by attribute 216.Preferably, at any point in the process described below, the user mayselect a main menu option to return to number/attribute prompt 212.

In the memory of memory unit 160, each valid recipe of the system,including the predetermined amounts of each of the four aqueouscompositions, corresponds to a recipe number. If the user knows therecipe number for the desired recipe, then the user should selectselection by recipe number 214. If the user selects selection by recipenumber 214 by touching an appropriate area of touch screen 90, then arecipe number prompt 218 prompts the user to enter a recipe number. Theuser will then enter the number corresponding to the desired paintcomposition recipe by touching appropriate areas of touch screen 90.After the user has entered the number, the screen will show that therecipe number is either valid or invalid at 220. If the recipe isinvalid, the user may enter another recipe number.

After entering a valid recipe number, the user may choose to verifystock availability 230 by touching an appropriate area of touch screen90. If the user chooses to verify stock availability 230, touch screen90 will prompt the user to enter a quantity 232. Touch screen 90 willthen show whether the available amounts of the four aqueous compositionsin reservoirs 12, 14, 16, 18 is sufficient or insufficient 234 to makethe desired amount of the desired recipe.

Control 80 tracks the available amounts of each type of aqueouscomposition by subtracting the amounts of the aqueous compositions asthey are supplied from reservoirs 12, 14, 16, 18. If reservoirs 12, 14,16, 18 are physically refilled, then the amount in supply reservoirs 12,14, 16, 18 can be reset as described below with reference to FIG. 5.After the amounts are reset, control 80 will again subtract amounts ofthe compositions as they are used. To determine whether availability issufficient for a particular quantity 232 of a particular recipe, control80 is programmed to subtract the necessary amount of each compositionneeded for the recipe from the current amount in the correspondingreservoir 12, 14, 16, 18. If the amount of any of the reservoirs 12, 14,16,18 is less than zero after the subtraction, then the availability isinsufficient. If the amount in all reservoirs 12, 14, 16, 18 is zero orgreater, then the amount is sufficient.

After either the user chooses not to verify stock availability 230 orafter the user completes verifying stock availability 230, touch screen90 prompts the user to enter a quantity 240 of paint to be made. Theuser then selects the quantity 240. In a preferred embodiment, the usermay select either 1 gallon for a 1 gallon paint bucket 20, or 5 gallonsfor a 5 gallon paint bucket 20. The user is then prompted to positionthe container 242 and to respond affirmatively that the container orreceiving reservoir 20 has been positioned. The attributes for the paintcomposition selected by the user are then displayed and the user isprompted to select start. Apparatus 10 then proceeds to automaticallyfill 244 receiving reservoir 20 with the appropriate amounts of eachaqueous composition to make the desired amount of the desired paintcomposition recipe.

Apparatus 10 will not proceed to supply compositions to receivingreservoir 20 unless position indicator 94 is depressed by receivingreservoir 20, indicating that receiving reservoir 20 is properlypositioned. If position indicator 94 is not depressed, then it will bein an open position and will not allow motors 40, 42, 44, 46 to receivepower. Also, if during the filling process, the position indicator isnot depressed, then motors 40, 42, 44, 46 will not receive power andapparatus 10 will cease supplying compositions to receiving reservoir20. This is done to assure that a receiving reservoir 20 is properlypositioned to receive the compositions. Likewise, if emergency stopswitch 92 is depressed, then it will be in an open position and will notallow the circuits for motors 40, 42, 44, 46 to be completed.

Referring now to FIG. 1, in filling receiving reservoir 20, control 80first calibrates scale 70 to read zero with the receiving reservoir 20seated on scale 70. Then, if the first composition is needed for therecipe, control 80 emits a signal to first solenoid 60 to open firstvalve 50 and a signal to first motor 40 to turn on, thereby poweringfirst pump 30. First pump 30 pumps a first aqueous composition fromfirst reservoir 12 through first valve 50 and into receiving reservoir20. While receiving reservoir 20 is being filled, scale 70 is emitting aflow amount signal to control 80 indicating the flow amount or weight ofthe first aqueous composition that has been supplied to receivingreservoir 20. Once the predetermined amount of the first composition hasbeen supplied to receiving reservoir 20, control 80 emits a signal tofirst solenoid 60 to close first valve 50 and a signal to first motor 40to turn off. Control 80 preferably sends signals to first solenoid 60and first motor 40 when scale 70 indicates that the amount of the firstcomposition in receiving reservoir 20 is the desired amount of the firstcomposition for the recipe minus an offset amount. The offset amountrepresents the amount of additional first composition that will besupplied to receiving reservoir 20 even after control 80 has sent thesignals to first solenoid 60 and first motor 40.

After supply of the first composition is completed, scale 70 is againcalibrated to zero. Typically there will be a delay of two to threeseconds after supply of the first composition is completed to allowscale 70 to be properly calibrated. Then, if the second composition isneeded for the recipe, control 80 emits a signal to second solenoid 62to open second valve 52 and a signal to second motor 42 to turn on,thereby powering second pump 32. Second pump 32 pumps the second aqueouscomposition from second reservoir 14 through second valve 52 and intoreceiving reservoir 20. While receiving reservoir 20 is being filled,scale 70 is emitting a flow amount signal to control 80 indicating theflow amount or weight of the second aqueous composition that has beensupplied to receiving reservoir 20. Once the predetermined amount of thesecond composition has been supplied to receiving reservoir 20, control80 emits a signal to second solenoid 62 to close second valve 52 and asignal to second motor 42 to turn off. Control 80 preferably sends thesignals to second solenoid 62 and second motor 42 when scale 70indicates that the amount of the second composition in receivingreservoir 20 is the desired amount of the second composition for therecipe minus an offset amount. As described above, the offset amountrepresents the amount of additional second composition that will besupplied to receiving reservoir 20 even after control 80 has sent thesignals to second solenoid 62 and second motor 42 to turn off.

After supply of the second composition is completed, scale 70 is againcalibrated to zero. Again, there is generally a delay of two to threeseconds after supply of the second composition is completed to allowscale 70 to be properly calibrated. Then, if the third composition isneeded for the recipe, control 80 emits a signal to third solenoid 64 toopen third valve 54 and a signal to third motor 44 to turn on, therebypowering third pump 34. Third pump 34 pumps the third aqueouscomposition from third reservoir 16 through third valve 54 and intoreceiving reservoir 20. While receiving reservoir 20 is being filled,scale 70 is emitting a flow amount signal to control 80 indicating theflow amount or weight of the third aqueous composition that has beensupplied to receiving reservoir 20. Once the predetermined amount of thethird composition has been supplied to receiving reservoir 20, control80 emits a signal to third solenoid 64 to close third valve 54 and asignal to third motor 44 to turn off. Control 80 preferably sends thesignals to third solenoid 64 and third motor 44 when scale 70 indicatesthat the amount of the third composition in receiving reservoir 20 isthe desired amount of the third composition for the recipe minus anoffset amount. As described above, the offset amount represents theamount of additional third composition that will be supplied toreceiving reservoir 20 even after control 80 has sent the signals tothird solenoid 64 and third motor 44 to turn off.

After supply of the third composition is completed, scale 70 is againcalibrated to zero. Again, there is generally a delay of two to threeseconds after supply of the third composition is completed to allowscale 70 to be properly calibrated. Then, if the fourth composition isneeded for the recipe, control 80 emits a signal to fourth solenoid 66to open fourth valve 56 and a signal to fourth motor 46 to turn on,thereby powering fourth pump 36. Fourth pump 36 pumps the fourth aqueouscomposition from fourth reservoir 18 through fourth valve 56 and intoreceiving reservoir 20. While receiving reservoir 20 is being filled,scale 70 is emitting a flow amount signal to control 80 indicating theflow amount or weight of the fourth aqueous composition that has beensupplied to receiving reservoir 20. Once the predetermined amount of thefourth composition has been supplied to receiving reservoir 20, control80 emits a signal to fourth solenoid 66 to close fourth valve 56 and asignal to fourth motor 46 to turn off. Control 80 preferably sends thesignals to fourth solenoid 66 and fourth motor 46 when scale 70indicates that the amount of the fourth composition in receivingreservoir 20 is the desired amount of the fourth composition for therecipe minus an offset amount. As described above, the offset amountrepresents the amount of additional fourth composition that will besupplied to receiving reservoir 20 even after control 80 has sent thesignals to fourth solenoid 66 and fourth motor 46 to turn off.

Referring now to FIG. 4, the user will then be prompted to choosewhether to mix again 246. If the user chooses to mix again 246, the userwill be returned to the quantity prompt 240. In this way, if the userwants to mix the same recipe, the user will not be required to gothrough the entire selection process again. If the user chooses not tomix again, then the user is returned to number or attribute prompt 212.

Referring back to the number or attribute prompt 212, if the userchooses to select the paint composition by attribute 216, the user willbe prompted to make a series of selections regarding the attributes orcharacteristics of the desired paint composition. An interior orexterior prompt 250 prompts the user to choose whether the paint will beused for an interior use or for an exterior use. A sheen prompt 252prompts the user to select a sheen for the paint composition. If theuser chooses interior use at prompt 250, then the choices at sheenprompt 252 preferably include flat, low sheen, egg shell, semi-gloss,and high gloss. A quality prompt 254 prompts the user to select aquality for the paint composition. Preferably, the choices at qualityprompt 254 include retail, professional, and economy, with retail beingthe highest quality, professional being intermediate quality, andeconomy being low quality. A color prompt 256 prompts the user to selecta color base for the paint. Preferably, the choices at color prompt 256include white, pastel, tinting, deep tone, and neutral. In a preferredembodiment, sheen prompt 252, quality prompt 254, and color prompt 256are all displayed simultaneously on touch screen 90. Those skilled inthe art will appreciate that the choices for sheen, quality, and colormay include choices different than those described herein. Also, otherprompts, such as a prompt for paint coverage attributes, may beincluded.

After the attributes have been selected, control 80 correlates thedesired attributes with a recipe number that will produce thoseattributes. The recipe number is then displayed and a valid or invaliddisplay 258 displays whether the selected attributes have yielded arecipe number is either valid or invalid. If the recipe number isinvalid, the user may enter different attributes. If the recipe numberis valid then a verify prompt 260 prompts the user to verify that theselected attributes are actually those desired by the user. If the usertouches an appropriate area of the screen to verify the attributechoices, then quantity prompt 240 prompts the user to enter a quantityof paint to be filled. The remainder of the filling process is identicalto that described above.

After supply of the fourth composition is completed, receiving reservoir20 may be removed. Then color additives may be added to the resultingaqueous paint composition. The adding of color additives to a baseaqueous paint composition and the colors to be added are well known inthe art. After the color additives, if any, are added the resultingcomposition is then preferably mixed by a shaker machine to produce thedesired paint. The paint is preferably then sold to a consumer, but itmay be sold to a paint supplier, who will in turn sell it to a consumer.

In a preferred embodiment, a number is selected as a password entrynumber, a number is selected as a maintenance override password, and anumber is selected as an inventory password. If the password entrynumber is entered by the user at recipe number prompt 218, then passwordprompt 310 prompts the user to enter a password. Referring now to FIGS.1 and 5, if the user enters the maintenance override password at thepassword prompt 310, then a maintenance override prompt 312 prompts theuser to select either solenoid control 314, recipe control 316, motorcontrol 318, input monitor 320, or load defaults 322.

If the user selects solenoid control 314, then an open/close prompt 330for each of the four solenoids 60, 62, 64, 66 allows the user to actuateeach of the four solenoids independently to close or open valves 50, 52,54, 56. Solenoid control 314 is useful for troubleshooting when problemsarise that might involve solenoids 60, 62, 64, 66 or valves 50, 52, 54,56.

If the user selects recipe control 316, then the user is prompted toenter a recipe number. Upon entering a recipe number, a weight prompt340 corresponding to each of the four aqueous compositions prompts theuser to enter or adjust the weight of that composition for the recipenumber entered. An offset prompt 342 corresponding to each of the fourcompositions allows the user to adjust the offset amounts discussedabove. Preferably, the offset amounts are adjusted after testing toassure that the offset amount represents the amount of additionalcomposition that will be supplied to receiving reservoir 20 even aftercontrol 80 has sent a close signal to a solenoid 60, 62, 64, or 66 andan off signal to motor 40, 42, 44, or 46 (see FIGS. 1-3) to stop theflow of the composition.

If the user selects motor control 318, then an on/off prompt 350 foreach of the four motors 40, 42, 44, 46 allows the user to independentlyturn each of the four motors 40, 42, 44, 46 on or off. Motor control 318is useful for troubleshooting when problems arise that might involvemotors 40, 42, 44, 46 or pumps 30, 32, 34, 36.

If the user selects input monitor 320, a switch indicator 356 allows theuser to monitor the status of emergency stop switch 92 and positionindicator 94 (see FIGS. 1-3). Input monitor 320 is useful fortroubleshooting problems that might involve switch 92 or positionindicator 94 (see FIGS. 1-3).

If the user selects load defaults 322, then all of the default valuesfor recipes, offsets, etc. will be reset to their original defaultvalues.

Referring back to password prompt 310, if the inventory password isentered at the password prompt then an inventory monitor 360 includes aview levels display 362 that displays current composition levels foreach of the supply reservoirs 12, 14, 16, 18 calculated by control 80 asdescribed above (see FIGS. 1-4). Also, a reset prompt 364 correspondingto each supply reservoir 12, 14, 16, 18 allows the current level foreach supply reservoir 12, 14, 16, 18 to be reset so that it shows thesupply reservoir being full. This should be done when one of the supplyreservoirs 12, 14, 16, 18 is refilled.

As discussed above, control 80 is preferably a computer system such as athe programmable logic control system described herein. Control 80 ispreferably programmed with a control program that causes control 80 toperform the various control and selection functions described above. Thecontrol program may be a program product in a variety of forms, and thepresent invention applies equally regardless of the particular type ofsignal bearing media to actually carry out the distribution of theprogram. Examples of signal bearing media include recordable type mediasuch as floppy disks and CD ROMS, and transmission type media such asdigital and analog communication links, including wireless communicationlinks. The program product tangibly embodies a program ofmachine-readable instructions executable by a computer system having anoperating system. The program product, in combination with a computersystem, directs the computer system, such as the PLC described herein,to perform the embodiments of the current invention. As such, thecontrol program can access Application Programmer Interfaces (APIs), ifavailable, or contain programming that allows the control program toprovide prompts to the user, distribute on/off signals to the motors,distribute open/close signals to the solenoids, correlate recipe numberswith associated paint attributes and composition weights, etc.Essentially, the control program will contain programming to allow it toperform any of the functionality associated with FIGS. 1-5 andassociated text.

The present invention provides the advantage of allowing a paintdistributor or paint store to produce a wide variety of water-basedpaints with only four aqueous compositions. The four aqueouscompositions may be stored and the aqueous paint composition may beproduced in the same location (i.e., the same building or complex ofbuildings) as the sale to an end paint consumer. This is made possiblebecause each of the four aqueous compositions may be stored for longperiods of time without significant settling. Accordingly, the presentinvention alleviates the current requirement for paint distributors orstores to maintain large inventories of a wide variety of paint typesand to guess about the types of paints that consumers might demand.

While the invention has been particularly shown and described withreference to preferred embodiments thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade therein without departing from the spirit and scope of theinvention.

1. A premixed aqueous pigment composition useful for formulating apigmented paint having a volume solids content of about 30% to about 70%and a Stormer viscosity of about 50 to about 250 KU, which premixedpigment composition contains other paint ingredients, which premixedpigment composition consists essentially of: (i) at least one pigment,(ii) at least one dispersant, (iii) at least one thickener, and (iv)water; wherein the dispersant(s) and the thickener(s) are stable whencombined with the pigment(s) and with the other paint ingredients. 2.The premixed pigment composition of claim 1, wherein the volume solidscontent is about 35% to about 50% and the Stormer viscosity is about 60to about 150 KU.
 3. The premixed pigment composition of claim 1, whereinthe dispersant comprises potassium tripolyphosphate.
 4. The premixedpigment composition of claim 1, wherein the thickener comprises acellulosic.
 5. The premixed pigment composition of claim 1, furtherconsisting essentially of at least one additive comprising a viscositycontrolling agent, with the additive being present in an amount of 10%or less by weight, based on the total weight of the premixed pigmentcomposition.
 6. A plurality of premixed compositions comprising twodifferent, but stable premixed aqueous compositions useful forformulating a paint, which comprises: (a) the premixed pigmentcomposition of claim 1; and (b) a resinous premixed binder compositionhaving volume solids content of about 25% to about 70% or a Brookfieldviscosity of less than about 100,000 centipoise at a shear rate of 1.25reciprocal seconds, which premixed binder composition consistsessentially of a water-borne resin containing binder having a Tg ofabout −430 degrees C. to about 70 degrees C. and water; wherein theingredients of the premixed compositions are stable when combined witheach other and with the ingredients of the other premixed compositionsin the plurality.
 7. The plurality of premixed aqueous compositions ofclaim 6, wherein the premixed binder composition has a volume solidscontent of about 30 to about 65% and a Brookfield viscosity of about 100to about 50,000 centipoise at a shear rate of 1.25 reciprocal seconds,and consists essentially of a water-borne resin containing binder havinga Tg of about −10 to about 60 degrees C.
 8. The plurality of premixedaqueous compositions of claim 6, wherein the premixed binder compositionfurther consists essentially of at least one additive comprising acoalescent, the additive being present in an amount of less than about10% by weight, based on the total weight of the premixed bindercomposition.
 9. A plurality of premixed compositions comprising threedifferent, but stable, premixed aqueous compositions, useful forformulating a paint product, which plurality comprises: (a) theplurality of premixed compositions of claim 6; and (b) a premixed lowresin composition which consists essentially of: (i) at least calcinedclay, ground limestone, and diatomaceous earth, (ii) at least onethickener, (iii) water, and (iv) optionally a resin containing binder;wherein the premixed low resin composition has a Stormer viscosity ofabout 50 to about 250 KU.
 10. The plurality of premixed aqueouscompositions of claim 9, wherein the premixed low resin composition hasa Stormer viscosity of about 60 to about 150 KU.
 11. The plurality ofpremixed aqueous compositions of claim 9, wherein the premixed bindercomposition further consists essentially of at least one additivecomprising a coalescent, with the additive being present in an amount ofless than about 20% by weight, based on the total weight of the premixedbinder composition.
 12. A premixed aqueous pigment composition having avolume solids content of about 30% to about 70%, a PVC of about 35% toabout 100%, and a Stormer viscosity of about 50 to about 250 KU, usefulfor formulating a pigmented paint product containing other paintingredients, which premixed aqueous composition consists essentially of:(i) at least one pigment, (ii) at least one dispersant, (iii) at leastone thickener, (iv) at least one film-forming or non-film-forming resin,and (v) water; wherein the dispersant(s), the thickener(s), and theresin(s) are stable when combined with the pigment(s) and with the otherpremixed composition ingredients and wherein the premixed composition isstable and free from settling.
 13. The premixed composition of claim 12,wherein the volume solids content is about 35% to about 50%, the PVC isabout 50 to about 100%, and the Stormer viscosity is about 60 to about150 KU.
 14. The premixed composition of claim 12, wherein the pigmentcomprises titanium dioxide.
 15. The premixed composition of claim 12,wherein the dispersant comprises potassium tripolyphosphate.
 16. Thepremixed composition of claim 12, wherein the thickener comprises acellulosic.
 17. The premixed composition of claim 12, wherein the resincomprises an acrylic resin.
 18. The premixed composition of claim 12,further consisting essentially of at least one additive comprising aviscosity controlling agent, with the additive being present in anamount of 10% or less by weight, based on the total weight of thepremixed composition.
 19. A plurality of premixed compositionscomprising two different, but stable premixed aqueous compositionsuseful for formulating a paint product, which plurality comprises: (a)the premixed pigment composition of claim 12; and (b) a premixed bindercomposition having volume solids content of about 25% to about 70% or aBrookfield viscosity of less than about 100,000 centipoise at a shearrate of 1.25 reciprocal seconds, which premixed binder compositionconsists essentially of a water-borne resin containing binder having aTg of about −430 degrees C. to about 70 degrees C. and water; whereinthe ingredients of the premixed compositions are stable when combinedwith each other and with the ingredients of the other premixedcompositions in the plurality.
 20. The plurality of premixedcompositions of claim 19, wherein the binder premixed composition has avolume solids content of about 30 to about 65% and a Brookfieldviscosity of about 100 to about 50,000 centipoise at a shear rate of1.25 reciprocal seconds, and consists essentially of a water-borne resincontaining binder having a Tg of about −10 to about 60 degrees C. 21.The plurality of premixed compositions of claim 19, wherein the premixedbinder composition further consists essentially of at least one additivecomprising a viscosity controlling agent, the additive being present inan amount of 10% or less by weight, based on the total weight of thepremixed binder composition.
 22. The plurality of premixed aqueouscompositions of claim 19, wherein the premixed binder compositionfurther consists essentially of at least one additive comprising acoalescent, with the additive being present in an amount of less thanabout 20% by weight, based on the total weight of the premixed bindercomposition.
 23. A plurality of premixed compositions comprising threedifferent, but stable, premixed aqueous compositions, useful forformulating a paint product, which plurality comprises: (a) theplurality of premixed compositions of claim 19; and (b) a premixedaqueous low resin composition which consists essentially of: (i) atleast calcined clay, ground limestone, and diatomaceous earth, (ii) atleast one thickener, (iii) water, and (iv) optionally a resin containingbinder; wherein the premixed low resin composition has a Stormerviscosity of about 50 to about 250 KU.
 24. The plurality of premixedaqueous compositions of claim 23, wherein the premixed low resincomposition has a volume solids content of about 35% to about 65%, a PVCof about 40% to about 100% and a Stormer viscosity of about 60 to about150 KU.